Strut with non-structural infill

ABSTRACT

An elongated structural ceiling grid member including an open-ended upper portion, an open-ended lower portion, and first and second flanges. The open-ended upper section is formed by a floor and a first set of second parallel and spaced sidewalls extending from and substantially perpendicular to the floor. The open-ended upper portion has an opening opposite the floor and defined by the first and second parallel and spaced sidewalls. The open-ended lower portion is formed by a ceiling and a second set of parallel and spaced sidewalls that extend from and are substantially perpendicular to the ceiling. The open-ended lower portion has a second opening opposite the ceiling and defined by the third and fourth parallel and spaced sidewalls. The first flange is attached to and extends perpendicular to the third parallel and spaced sidewall and the second flange is attached to and extends perpendicular to the fourth parallel and spaced sidewall.

This is a Continuation of application Ser. No. 15/288,551 filed Oct. 7,2016. The disclosure of the prior application is hereby incorporated byreference herein in its entirety.

FIELD OF THE INVENTION

This invention relates to ceiling grids, comprised of intersecting andperpendicular rows of elongated struts or members, that are attached toand suspended from ceilings of rooms and other building spaces, such asoffice spaces, storage areas, and data centers, to function as theframework for directly and/or indirectly supporting other structuralmembers and room or building accessories. In particular, this inventionrelates to elongated struts or members, both structural andnon-structural, that can be used in such a ceiling grid.

BACKGROUND OF THE INVENTION

Ceiling grids comprised of intersecting and perpendicular rows ofelongated struts or members, both structural and non-structural strutsor members, have been in use for decades. Those ceiling grids areusually directly attached to and suspended from the structure comprisingthe ceiling of a room or other building space, such as a concrete slab.The elongated structural struts or members of those ceiling gridsdirectly or indirectly support other structural members and room orbuilding accessories, such as light fixtures, HVAC conduits, sprinklersystems, etc., in the rooms or other building spaces in which they areinstalled.

In certain environments, it is desirable that the ceiling grids includeelongated structural struts or members that have (1) the desired loadcapacity and (2) an architectural or aesthetic finish when viewed fromunderneath the ceiling grid. In addition, it is often desirable that avariety of other structural members and room or building accessories canbe attached to or otherwise supported by the elongated structural strutsor members at any location along the elongated structural struts ormembers.

While some elongated structural struts or members for ceiling grids havebeen developed that have (1) the desired load bearing capacity, (2) anarchitectural or aesthetic appearance when viewed from underneath theceiling grid, and (3) the capability that other structural members androom or building accessories can be attached to the elongated structuralstruts or members at any location along the struts or members, there isalways a need for elongated structural struts or members for ceilinggrids with improved load bearing capacity and/or aesthetic appearance,and with the capability that other structural struts or members and roomor building accessories can be attached to the elongated structuralstruts or members at any location along the struts or members.

In addition, there is always a need for improved elongatednon-structural struts or members for ceiling grids that can be readilyand securely attached to the elongated structural struts or members ofthose grids and have an architectural or aesthetic finish when viewedfrom underneath the grids.

This invention addresses those needs, as well as other needs that arereadily apparent to those of skill in the art.

SUMMARY OF THE INVENTION

An elongated structural ceiling grid member according to one embodimentof this invention may include an open-ended upper portion formed by afloor and a first set of parallel and spaced sidewalls extending fromand substantially perpendicular to the floor. Each of the first set ofparallel and spaced sidewalls may include a lower flat wall section andan upper section that is continuous with the lower flat wall section andextends towards the other of the first set of parallel and spacedsidewalls. The upper-ended upper portion may have a first opening (1)opposite the floor and (2) defined by the upper sections of the firstset of parallel and spaced sidewalls. The elongated structural ceilinggrid member of this embodiment may also include an open-ended lowerportion formed by a ceiling and a second set of parallel and spacedsidewalls extending from and substantially perpendicular to the ceiling.Each of the second set of parallel and spaced sidewalls may include anupper flat wall section and a lower section that is continuous with theupper flat wall section and extends towards the other of the second setof parallel spaced sidewalls. The open-ended lower portion may have asecond opening (1) opposite the ceiling and the first opening and (2)defined by the second set of parallel and spaced sidewalls. Theelongated structural ceiling grid member of this embodiment may alsoinclude first and second flanges. The open-ended upper portion, theopen-ended lower portion and the first and second flanges may havelongitudinal axes that are substantially parallel to the longitudinalaxis of the elongated structural ceiling grid member. The floor andceiling may be integral. The first flange may be attached to the lowersection of one of the second set of parallel and spaced sidewalls andextend substantially perpendicular in the lateral direction to the upperflat wall section of that parallel and spaced sidewall. The secondflange may be attached to the lower section of the other of the secondset of parallel and spaced sidewalls and extend substantiallyperpendicular to the upper flat wall section of that parallel and spacedsidewall.

In some embodiments of the elongated structural ceiling grid members ofthis invention, the upper sections of the first set of parallel andspaced sidewalls may be hooks having free ends that are located invertical planes between the vertical planes of the lower flat wallsections of the first set of parallel and spaced sidewalls.

In other embodiments of the elongated structural ceiling grid members ofthis invention, the lower sections of the second set of parallel andspaced sidewalls may be hooks that have free ends that are located invertical planes between the vertical planes of the upper flat wallsections of the second set of parallel and spaced sidewalls.

In yet other embodiments of the elongated structural ceiling gridmembers of this invention, the first and second flanges may be elongatedbars that extend laterally beyond and outside of the upper flat wallportions of the second set of parallel and spaced sidewalls.

In further embodiments of the elongated structural ceiling grid membersof this invention, the lower flat wall portions of the first set ofparallel and spaced sidewalls are in substantially the same planes asthe upper flat wall portions of the second set of parallel and spacedsidewalls.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an elongated structural strut forceiling grids according to one embodiment of this invention.

FIG. 2 is an elevation view of the elongated structural strut forceiling grids of FIG. 1.

FIG. 3 is a top perspective view, partially sectionalized and partiallyin phantom for clarity, of four of the elongated structural strut forceiling grids illustrated in FIGS. 1 and 2, joined by a connector toform intersecting and perpendicular rows of the struts.

FIG. 4 is an elevation view of three of the elongated structural strutfor ceiling grids illustrated in FIGS. 1 and 2, joined by a connector toform a T-intersection of the struts.

FIG. 5 is a top perspective view of an elongated non-structural strutfor ceiling grids according to one embodiment of this invention.

FIG. 6 is an elevation view of the elongated non-structural strut forceiling grids of FIG. 5.

FIG. 7 is a top perspective view of two of the elongated non-structuralstrut of FIGS. 5 and 6 attached to an elongated structural strut ofFIGS. 1 and 2, to form an intersection of perpendicular rows of theelongated non-structural struts and the elongated structural struts.

FIG. 8 is a top perspective view of a ceiling grid comprised of aplurality of the elongated structural strut for ceiling grids of FIGS. 1and 2 and a plurality of the elongated non-structural strut of FIGS. 5and 6.

FIGS. 9A, 9B, 9C and 9D are a series of schematic views illustrating howthe connector of FIG. 3 can be attached to the elongated structuralstrut for ceiling grids of FIGS. 1 and 2.

FIG. 10 is a top perspective view, partially in phantom for clarity, oftwo of the elongated structural strut for ceiling grids illustrated inFIGS. 1 and 2, joined by a connector to form a corner of a ceiling grid.

DETAILED DESCRIPTION

As stated, FIGS. 1 and 2 illustrate one embodiment of an elongatedstructural strut for ceiling grids of this invention, elongatedstructural strut 10. Elongated structural strut 10 has a longitudinalaxis that extends the length of elongated structural strut 10.

Elongated structural strut 10 includes upper portion 12, lower portion14 and lower flanges 16 and 18. In this embodiment of the elongatedstructural struts of the invention, upper portion 12 and lower portion14 are integral, and extruded from stock of the same material. In otherembodiments of the elongated structural struts of this invention, upperportion 12 and lower portion 14 can be two or more separate componentsjoined together by welding or any other well-known fasteningmethod/mechanism.

Upper portion 12 includes floor 20 and sidewalls 22 and 24, which, inthis embodiment of the elongated structural struts of this invention,are integral. In other embodiments of the elongated structural struts ofthis invention, the floor and sidewalls of the upper portion can bemultiple components joined together.

In this embodiment of the elongated structural struts of the invention,sidewalls 22 and 24 are parallel, mirror images that are substantiallyperpendicular to floor 20.

Also, in this embodiment of the elongated structural struts of theinvention, sidewall 22 includes flat wall portion 23 and hook 26. Flatwall portion 23 begins at a longitudinal edge of floor 20 and extendsupward. Hook 26 is formed by the upper portion of sidewall 22, above andcontinuous with flat wall portion 23.

Similarly, in this embodiment of the elongated structural struts of theinvention, sidewall 24 includes flat wall portion 25 and hook 28. Flatwall portion 25 begins at the other longitudinal edge of floor 20 andextends upward. Hook 28 is formed by the upper portion of sidewall 24,above and continuous with flat wall portion 25.

Floor 20 and sidewalls 22 and 24 define upper chamber 50 with opening 52defined by hooks 26 and 28.

The function of hooks 26 and 28 is to provide portions of sidewalls 22and 24 that extend inwardly from flat wall portions 23 and 25,respectively, without closing opening 52. In use, hooks 26 and 28 canengage support members that are used to attach elongated structuralstrut 10 to a ceiling, as explained below. In other embodiments of theelongated structural struts of the invention, the upper portions of thesidewalls can have any shape that results in those portions extendinginwardly, without closing the opening between the sidewalls. Oneadvantage of hooks 26 and 28 over other “shapes” is that hooks 26 and 28provide a “loop” to firmly engage a rod, flange, etc. that fits into andis received in the “loop.”

Also, the sidewalls of the upper portions of other embodiments of theelongated structural struts of this invention do not have to includeflat wall portions, such as flat wall portions 23 and 25. Rather, thesidewalls can have any configuration and/or shape that results in thesidewalls partially defining a chamber between them.

Lower portion 14 includes ceiling 30 and sidewalls 32 and 34, which, inthis embodiment are integral. In other embodiments of the elongatedstructural struts of this invention, the ceiling and sidewalls of thelower portion can be multiple components joined together.

In this embodiment of the elongated structural struts of this invention,sidewalls 32 and 34 are parallel, mirror images that are substantiallyperpendicular to ceiling 30.

Also, in this embodiment of the elongated structural struts of thisinvention, sidewall 32 includes flat wall portion 33 and hook 36. Flatwall portion 33 begins at a longitudinal edge of ceiling 30 and extendsdownward. Hook 36 is formed by the lower portion of sidewall 32, belowand continuous with flat wall portion 33.

Similarly, in this embodiment of the elongated structural struts of theinvention, sidewall 34 includes flat wall portion 35 and hook 38. Flatwall portion 35 begins at the other longitudinal edge of ceiling 30 andextends downward. Hook 38 is formed by the lower portion of sidewall 34,below and continuous with flat wall portion 35.

Ceiling 30 and sidewalls 32 and 34 define lower chamber 54 with opening56 defined by hooks 36 and 38 (and the innermost ends of flanges 16 and18).

The function of hooks 36 and 38 is to provide portions of sidewalls 32and 34 that extend inwardly from flat wall portions 33 and 35,respectively, without closing opening 56. In use, hooks 36 and 38 canengage or otherwise support other structural members, room and buildingaccessories, apparatus to support room and building accessories, etc. Inother embodiments of the elongated structural struts of this invention,the lower portions of the sidewalls can have any shape that results inthose portions extending inwardly, without closing the opening betweenthe sidewalls. As stated above, one advantage of hooks 36 and 38 overother “shapes” is that hooks 36 and 38 provide a “loop” to firmly engagea rod, flange, etc. that fits into and is received in the “loop.”

Also, the sidewalls of the lower portions of other embodiments of theelongated structural struts of this invention do not have to includeflat wall portions, such as flat wall portions 33 and 35. Rather, thesidewalls can have any configuration and/or shape that results in thesidewalls partially defining a chamber between them.

As can be determined from FIGS. 1 and 2, in this embodiment of theelongated structural struts of the invention, flat wall portions 23 and33 of sidewalls 22 and 32 are in substantially the same planes and flatwall portions 25 and 35 of sidewalls 24 and 34 are in substantially thesame planes.

Flange 16 is attached to hook 36 of sidewall 32 by spot welds, such asspot welds 40, as shown in FIG. 2. Flange 16 is oriented substantiallyperpendicular to flat wall portion 33 of sidewall 32 in the lateraldirection and abuts sidewall 32 at the apex of hook 36. Flange 16extends laterally beyond and outside of flat wall portion 33 to providea surface to support other structural members, room and buildingaccessories, etc. The inner surface of flange 16 is in substantially thesame plane as the innermost surface of hook 36.

Similarly, flange 18 is attached to hook 38 of sidewall 34 by spot welds42, as shown in FIGS. 1 and 2. Flange 18 is oriented substantiallyperpendicular to flat wall portion 35 of sidewall 34 in the lateraldirection and abuts sidewall 34 at the apex of hook 38. Flange 18extends laterally beyond and outside of flat wall portion 35 to providea surface to support other structural members, room and buildingaccessories, etc. The inner surface of flange 18 is in substantially thesame plane as the innermost surface of hook 38.

While, in this embodiment of the elongated structural struts of thisinvention, flanges 16 and 18 are elongated bars attached to lowerportion 14, in other embodiments of the elongated structural struts ofthis invention, flanges 16 and 18 can be integral with lower portion 14.Also, in yet other embodiments of the elongated structural struts ofthis invention, flanges 16 and 18 can have a shape other than anelongated bar, as long as they include a portion that can support otherstructural members and room and building accessories such as lightfixtures, HVAC conduits, piping, etc.

As can be determined from FIGS. 1 and 2, each of upper portion 12, lowerportion 14 and flanges 16 and 18 has a longitudinal axis that issubstantially parallel to the longitudinal axis of elongated structuralstrut 10.

As stated, FIG. 3 illustrates four of the elongated structural strut forceiling grids illustrated in FIGS. 1 and 2 and described above,elongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d),connected at one of their ends to form intersecting and perpendicularrows of the struts. Elongated structural struts 10 ^(a), 10 ^(b), 10^(c) and 10 ^(d) are joined by connector assembly 44, which includeswing member 46 and U-shaped connector 48.

Wing member 46 is a flat member that includes center portion 59 andintegral wings 58 ^(a), 58 ^(b), 58 ^(c) and 58 ^(d) that extend outwardfrom center portion 59. Wings 58 ^(a), 58 ^(b), 58 ^(c) and 58 ^(d) areoriented at 90° from each other. Wings 58 ^(a), 58 ^(b), 58 ^(c) and 58^(d) are affixed to elongated structural struts 10 ^(a), 10 ^(b), 10^(c) and 10 ^(d), respectively, as described below.

U-shaped connector 48 is a continuous member formed of top portion 60,sidewalls 62 and 64 and mating flanges 66 and 68. Mating flange 66 mateswith wing 58 ^(d) and is affixed to elongated structural strut 10 ^(d)with wing 58 ^(d). Mating flange 68 mates with wing 58 ^(b) and isaffixed to elongated structural strut 10 ^(b) with wing 58 ^(b).

While, in this embodiment of the invention, wing member 46 and U-shapedconnector 48 are separate components, in other embodiments, they can beintegral. Also, in other embodiments, the connector assembly can be ofany shape or configuration as long as it has surfaces that can beattached to four elongated structural struts that are arranged to formintersecting and perpendicular rows of the struts and a surface thatenables it to be connected to a ceiling rod assembly, as describedbelow, or to any other apparatus employed to attach and suspend theconnector assembly to and from a ceiling.

In this embodiment of the invention, wing 58 ^(a) is attached toelongated structural strut 10 ^(a) by bolt 70 ^(a) and retaining block72 ^(a), wing 58 ^(b) and mating flange 68 are attached to elongatedstructural strut 10 ^(b) by bolt 70 ^(b) and retaining block 72 ^(b),wing 58 ^(c) is attached to elongated structural strut 10 ^(c) by bolt70 ^(c) and retaining block 72 ^(c), and wing 58 ^(d) and mating flange66 are attached to elongated structural strut 10 ^(d) by bolt 70 ^(d)and retaining block 72 ^(d), respectively. Bolts 70 ^(a), 70 ^(b), 70^(c) and 70 ^(d) have external threads that threadedly engage internalthreads of holes in retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72^(d), respectively. The shafts of bolts 70 ^(a), 70 ^(b), 70 ^(c) and 70^(d) are received in holes in wings 58 ^(a), 58 ^(b), 58 ^(c) and 58^(d), respectively. The shafts of bolts 70 ^(b) and 70 ^(d) are alsoreceived in holes in mating flanges 68 and 66, respectively. Retainingblocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) have a width less than, buta length greater than, the width of openings 52 ^(a), 52 ^(b), 52 ^(c)and 52 ^(d) of upper portions 12 ^(a), 12 ^(b), 12 ^(c) and 12 ^(d) ofelongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d),respectively, for reasons described below.

Connector assembly 44 can be attached to elongated structural struts 10^(a), 10 ^(b), 10 ^(c) and 10 ^(d) in at least the following ways.

One way is illustrated, in part, by FIGS. 9A-9D. First, before connectorassembly 44 is placed on elongated structural struts 10 ^(a), 10 ^(b),10 ^(c) and 10 ^(d), bolt 70 ^(a) and retaining block 72 ^(a) areloosely connected to wing 58 ^(a), bolt 70 ^(b) and retaining block 72^(b) are loosely connected to wing 58 ^(b) and mating flange 68, bolt 70^(c) and retaining block 72 ^(c) are loosely connected to wing 58 ^(c),and bolt 70 ^(d) and retaining block 72 ^(d) are loosely connected towing 58 ^(d) and mating flange 66 (the loose connection of bolt 70 ^(b)and retaining block 72 ^(b) to wing 58 ^(b) and mating flange 68 isillustrated in FIG. 9A). Connector assembly 44 is then positioned aboveelongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d), withwing 58 ^(a) located above elongated structural strut 10 ^(a), wing 58^(b) and mating flange 68 located above elongated structural strut 10^(b), wing 58 ^(c) located above elongated structural strut 10 ^(c), andwing 58 ^(d) and mating flange 66 located above elongated structuralstrut 10 ^(d). Alternatively, if connector assembly 44 is alreadyinstalled, elongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10^(d) are positioned below connector assembly 44, with elongatedstructural strut 10 ^(a) located below wing 58 ^(a), elongatedstructural strut 10 ^(b) below wing 58 ^(b) and mating flange 68,elongated structural strut 10 ^(c) below wing 58 ^(c), and elongatedstructural strut 10 ^(d) below wing 58 ^(d) and mating flange 66.

Either way, retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) arepositioned relative to openings 52 ^(a), 52 ^(b), 52 ^(c) and 52 ^(d)such that the widths of retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and72 ^(d) are substantially aligned with openings 52 ^(a), 52 ^(b), 52^(c) and 52 ^(d), so that retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and72 ^(d) can fit through openings 52 ^(a), 52 ^(b), 52 ^(c) and 52 ^(d),respectively. The alignment of retaining block 72 ^(b) with opening 52^(b) is illustrated in FIG. 9A.

Next, connector assembly 44 is lowered, or elongated structural struts10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d) are raised (if connector assembly44 is already installed), until retaining blocks 72 ^(a), 72 ^(b), 72^(c) and 72 ^(d) pass through openings 52 ^(a), 52 ^(b), 52 ^(c) and 52^(d) and are received in chambers 50 ^(a), 50 ^(b), 50 ^(c) and 50 ^(d),respectively. As noted above, the width of retaining blocks 72 ^(a), 72^(b), 72 ^(c) and 72 ^(d) is less than the widths of openings 52 ^(a),52 ^(b), 52 ^(c) and 52 ^(d), respectively. The passing of retainingblock 72 ^(b) through opening 52 ^(b) into chamber 50 ^(b) isillustrated in FIG. 9B.

Once the top surfaces of retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and72 ^(d) pass below the free end of hooks 26 ^(a) and 28 ^(a), hooks 26^(b) and 28 ^(b), hooks 26 ^(c) and 28 ^(c), and hooks 26 ^(d) and 28^(d), respectively, retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72^(d) are rotated such that portions of retaining blocks 72 ^(a), 72^(b), 72 ^(c) and 72 ^(d) overlap the free ends of those hooks. Therotation of retaining block 72 ^(b) is illustrated in FIG. 9C.

Bolts 70 ^(a), 70 ^(b), 70 ^(c) and 70 ^(d) are then tightened untilretaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) firmly engage thefree ends of hooks 26 ^(a) and 28 ^(a), hooks 26 ^(b) and 28 ^(b), hooks26 ^(c) and 28 ^(c), and hooks 26 ^(d) and 28 ^(d), respectively. Thetightening of bolt 70 ^(b) and engagement of retaining block 72 ^(b)with the free ends of hooks 26 ^(b) and 28 ^(b) are illustrated in FIG.9D.

Another way of connecting connector assembly 44 to elongated structuralstruts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d), i.e., connecting wing 58^(a) to elongated structural strut 10 ^(a) by bolt 70 ^(a) and retainingblock 72 ^(a), wing 58 ^(b) and mating flange 68 to elongated structuralstrut 10 ^(b) by bolt 70 ^(b) and retaining block 72 ^(b), wing 58 ^(c)to elongated structural strut 10 ^(c) by bolt 70 ^(c) and retainingblock 72 ^(c), and wing 58 ^(d) and mating flange 66 to elongatedstructural strut 10 ^(d) by bolt 70 ^(d) and retaining block 72 ^(d), isas follows. Connector assembly 44 is placed on elongated structuralstruts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d) such that wing 58 ^(a) isabove elongated structural strut 10 ^(a), wing 58 ^(b) and mating flange68 are above elongated structural strut 10 ^(b), wing 58 ^(c) is aboveelongated structural strut 10 ^(c), and wing 58 ^(d) and mating flange66 are above elongated structural strut 10 ^(d), but without bolts 70^(a), 70 ^(b), 70 ^(c) and 70 ^(d) and retaining blocks 72 ^(a), 72^(b), 72 ^(c) and 72 ^(d) attached thereto. Alternatively, if connectorassembly 44 is already installed, elongated structural struts 10 ^(a),10 ^(b), 10 ^(c) and 10 ^(d) are positioned below connector assembly 44such that elongated structural strut 10 ^(a) is below wing 58 ^(a),elongated structural strut 10 ^(b) is below wing 58 ^(b) and matingflange 68, elongated structural strut 10 ^(c) is below wing 58 ^(c), andelongated structural strut 10 ^(d) is below wing 58 ^(d) and matingflange 66, but without bolts 70 ^(a), 70 ^(b), 70 ^(c) and 70 ^(d) andretaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) attached thereto.

Once connector assembly 44 and elongated structural struts 10 ^(a), 10^(b), 10 ^(c) and 10 ^(d) are in the proper relative position, bolts 70^(a), 70 ^(b), 70 ^(x) and 70 ^(d) are inserted through the holes inwing 58 ^(a), wing 58 ^(b) and mating flange 68, wing 58 ^(c), and wing58 ^(d) and mating flange 66, respectively. The lower ends of bolts 70^(a), 70 ^(b), 70 ^(c) and 70 ^(d) extend into upper chambers 50 ^(a),50 ^(b), 50 ^(c) and 50 ^(d) through openings 52 ^(a), 52 ^(b), 52 ^(c)and 52 ^(d), respectively. Retaining blocks 72 ^(a), 72 ^(b), 72 ^(c)and 72 ^(d) are then positioned on the threaded ends of bolts 70 ^(a),70 ^(b), 70 ^(c) and 70 ^(d), respectively, such that areas of retainingblocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) overlap with hooks 26 ^(a)and 28 ^(a), hooks 26 ^(b) and 28 ^(b), hooks 26 ^(c) and 28 ^(c), andhooks 26 ^(d) and 28 ^(d), respectively. Bolts 70 ^(a), 70 ^(b), 70 ^(c)and 70 ^(d) are then tightened until retaining blocks 72 ^(a), 72 ^(b),72 ^(c) and 72 ^(d) firmly engage hooks 26 ^(a) and 28 ^(a), hooks 26^(b) and 28 ^(b), hooks 26 ^(c) and 28 ^(c), and hooks 26 ^(d) and 28^(d), respectively.

Yet another way of connecting connector assembly 44 to elongatedstructural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10 ^(d), i.e.,connecting wing 58 ^(a) to elongated structural strut 10 ^(a) by bolt 70^(a) and retaining block 72 ^(a), wing 58 ^(b) and mating flange 68 toelongated structural strut 10 ^(b) by bolt 70 ^(b) and retaining block72 ^(b), wing 58 ^(c) to elongated structural strut 10 ^(c) by bolt 70^(c) and retaining block 72 ^(c), and wing 58 ^(d) and mating flange 66to elongated structural strut 10 ^(d) by bolt 70 ^(d) and retainingblock 72 ^(d), is as follows. Retaining blocks 72 ^(a), 72 ^(b), 72 ^(c)and 72 ^(d) are positioned in upper chambers 50 ^(a), 50 ^(b), 50 ^(c)and 50 ^(d) such that portions of retaining blocks 72 ^(a), 72 ^(b), 72^(c) and 72 ^(d) overlap with hooks 26 ^(a) and 28 ^(a), hooks 26 ^(b)and 28 ^(b), hooks 26 ^(c) and 28 ^(c) and hooks 26 ^(d) and 28 ^(d),respectively. Springs, such as springs 57 ^(a), 57 ^(b), 57 ^(x) and 57^(d) in FIG. 3, are positioned in upper chambers 50 ^(a), 50 ^(b), 50^(c) and 50 ^(d) between retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and72 ^(d) and floors 20 ^(a), 20 ^(b), 20 ^(c) and 20 ^(d) of upperportions 12 ^(a), 12 ^(b), 12 ^(c) and 12 ^(d), respectively, to “push”retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d) in fixedpositions against the free ends of hooks 26 ^(a) and 28 ^(a), hooks 26^(b) and 28 ^(b), hooks 26 ^(c) and 28 ^(c) and hooks 26 ^(d) and 28^(d), respectively. Bolts 70 ^(a), 70 ^(b), 70 ^(c) and 70 ^(d) are theninserted through the holes in wing 46 ^(a), wing 46 ^(b) and matingportion 68, wing 46 ^(c) and wing 46 ^(d) and mating portion 66, andtightened to firmly engage retaining blocks 72 ^(a), 72 ^(b), 72 ^(c)and 72 ^(d) against the free ends of hooks 26 ^(a) and 28 ^(a), hooks 26^(b) and 28 ^(b), hooks 26 ^(c) and 28 ^(c), and hooks 26 ^(d) and 28^(d), respectively.

Connector assembly 44 can be attached to and suspended from thestructure comprising a ceiling of a room or other building area, such asa concrete slab, as follows. One end of a ceiling rod assembly, such asceiling rod assembly 61 in FIG. 3, is attached to the ceiling structure.The other end of ceiling rod assembly 61 is attached to top portion 60of U-shaped connector 48.

As stated, FIG. 4 illustrates three of the elongated structural strutfor ceiling grids illustrated in FIGS. 1 and 2 and described above,elongated structural struts 10′, 10″ and 10′″, joined at one of theirends to form a T-intersection of a ceiling grid (elongated structuralstrut 10′″ is not shown in FIG. 4, but is behind and axially in linewith elongated structural strut 10″). Elongated structural struts 10′,10″ and 10′″ are joined by connector assembly 44′, which includesT-shaped member 46′ and U-shaped connector 48′.

T-shaped member 46′ is a flat member that includes center portion 59′(not shown) and integral wings 58′, 58″ and 58′″ that (1) extend outwardfrom center portion 59′ and (2) are oriented 90° to each other to form a“T” (wing 58′″ is not shown in FIG. 4, but is behind and in the sameplanes as wing 58″).

The same as U-shaped connector 48, U-shaped connector 48′ is acontinuous member formed of top portion 60′, sidewalls 62′ and 64′ andmating flanges 66′ and 68′ (sidewall 64′ and mating flange 68′ are notshown in FIG. 4).

While in this embodiment of the invention, T-shaped member 46′ andU-shaped connector 48′ are separate components, in other embodiments,they can be integral. Also, in other embodiments, the connector assemblycan be of any shape or configuration as long as it has surfaces that canbe attached to the three elongated structural struts forming theT-intersection and a surface that enables it to be connected to aceiling rod assembly, or to any other apparatus employed to attach andsuspend the ceiling grid to and from a ceiling.

Connector assembly 44′ can be attached to elongated structural struts10′, 10″ and 10′″ in the same ways that connector assembly 44 can beattached to elongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10^(d). Specifically, wing 58′ is attached to elongated structural strut10′ by bolt 70′ and retaining block 72′, wing 58″ and mating flange 66′are attached to elongated structural strut 10″ by bolt 70″ and retainingblock 72″, and wing 58′″ and mating flange 68′ are attached to elongatedstructural strut 10′″ by bolt 70′″ and retaining block 72′″ (bolt 70′″and retaining block 72′″ are not shown in FIG. 4). Like bolts 70 ^(a),70 ^(b), 70 ^(c) and 70 ^(d) and retaining blocks 72 ^(a), 72 ^(b), 72^(c) and 72 ^(d), bolts 70′, 70″ and 70′″ have external threads thatthreadedly engage internal threads of holes in retaining blocks 72′, 72″and 72′″, respectively. Also, like retaining blocks 72 ^(a), 72 ^(b), 72^(c) and 72 ^(d), retaining blocks 72′, 72″ and 72′″ have a width lessthan, but a length greater than, the width of openings 52′, 52″ and 52′″of upper portions 12′, 12″ and 12′″ of elongated structural struts 10′,10″ and 10′″, respectively.

The end result is that retaining blocks 72′, 72″ and 72′″ are receivedin upper chambers 50′, 50″ and 50′″ of upper portions 12′, 12″ and 12′″of elongated structural struts 10′, 10″ and 10′″ and firmly engage thefree ends of hooks 26′ and 28′, hooks 26″ and 28″, and hooks 26′″ and28′″, respectively.

In this embodiment, when elongated structural struts 10′ and 10″ arejoined by connector assembly 44′, flanges 16′ (not shown) and 18′ abutflange 18″, as shown in FIG. 4.

Connector assembly 44′ can be attached to and suspended from ceilingstructure by ceiling rod assembly 61′ in the same manner that connectorassembly 44 can be attached to and suspended from ceiling structure byceiling rod assembly 61.

In other embodiments, a connector assembly other than connector assembly44′ can be used to join elongated structural struts 10′, 10″ and 10′″ inthe configuration of a T-intersection.

As stated, FIG. 10 illustrates two of the elongated structural strut forceiling grids illustrated in FIGS. 1 and 2 and described above,elongated structural struts 10 ^(x) and 10 ^(y), joined at one of theirends to form a corner of a ceiling grid. Elongated structural struts 10^(x) and 10 ^(y) are joined by L-shaped member 46 ^(x).

In this embodiment, L-shaped member 46 ^(x) is a flat member thatincludes center portion 59 ^(x) and integral wings 58 ^(x) and 58 ^(y)that (1) extend outward from center portion 59 ^(x) and (2) are oriented90° to each other to form an “L.” In other embodiments, the member thatjoins the elongated structural struts can be of any shape orconfiguration as long as it has surfaces that can be attached to the twoelongated structural struts forming the grid corner.

L-shaped member 46 ^(x) can be attached to elongated structural struts10 ^(x) and 10 ^(y) in the same ways that connector assembly 44 can beattached to elongated structural struts 10 ^(a), 10 ^(b), 10 ^(c) and 10^(d). Specifically, wing 58 ^(x) is attached to elongated structuralstrut 10 ^(x) by bolt 70 ^(x) and retaining block 72 ^(x) and wing 58^(y) is attached to elongated structural strut 10 ^(y) by bolt 70 ^(y)and retaining block 72 ^(y). Like bolts 70 ^(a), 70 ^(b), 70 ^(c) and 70^(d) and retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d), bolts70 ^(x) and 70 ^(y) have external threads that threadedly engageinternal holes in retaining blocks 72 ^(x) and 72 ^(y), respectively.Also, like retaining blocks 72 ^(a), 72 ^(b), 72 ^(c) and 72 ^(d),retaining blocks 72 ^(x) and 72 ^(y) have a width less than, but alength greater than, the width of openings 52 ^(x) and 52 ^(y) of upperportions 12 ^(x) and 12 ^(y) of elongated structural struts 10 ^(x) and10 ^(y), respectively.

The end result is that retaining blocks 72 ^(x) and 72 ^(y) are receivedin upper chambers 50 ^(x) and 50 ^(y) of upper portions 12 ^(x) and 12^(y) of elongated structural struts 10 ^(x) and 10 ^(y) and firmlyengage the free ends of hooks 26 ^(x) and 28 ^(x) and hooks 26 ^(y) and28 ^(y), respectively.

As stated, FIGS. 5 and 6 illustrate one embodiment of a non-structuralelongated member, non-structural elongated member 74, which can be usedin a ceiling grid with the elongated structural struts of thisinvention.

Non-structural elongated member 74 includes upper portion 76, web 78 andflange portion 80. While, in this embodiment of the invention, upperportion 76, web 78 and flange portion 80 are integral, in otherembodiments, they can be comprised of two or more components, welded orotherwise fastened together.

Upper portion 76 includes floor 81 and spaced and parallel sidewalls 82and 84 that extend upward from the two longitudinal edges of floor 81 toform a U-shape with floor 81. Sidewall 82 includes threads 86 on itsinner surface, and sidewall 84 includes threads 88 on its inner surface.Floor 81 and sidewalls 82 and 84 form or define threaded slot 77.Threads 86 and 88 are offset one half turn vertically from each other,as shown in FIG. 6. That is, each peak of thread 86 is diametricallyopposed by a valley of thread 88, and each valley of thread 86 isdiametrically opposed by a peak of thread 88.

Flange portion 80 is oriented substantially perpendicular to web 78. Thebottom surface of flange portion 80 is what is visible to occupants ofthe room or building space that includes a ceiling grid with one or morenon-structural elongated members 74.

As stated, FIG. 7 illustrates a pair of the non-structural elongatedmember of FIGS. 5 and 6, non-structural elongated members 74′ and 74″,attached on opposite sides of elongated structural strut 10, to formintersecting and perpendicular rows of the elongated structural strutsand the non-structural elongated members. Specifically, non-structuralelongated member 74′ is attached to one side of elongated structuralstrut 10 by connector 90, and non-structural elongated member 74″ isattached to the opposite side of elongated structural strut 10 byconnector 92.

In this embodiment, connectors 90 and 92 are L-shaped. The bottom armsof connectors 90 and 92 are attached to non-structural elongated members74′ and 74″ by bolts 94 and 96 that threadedly engage threaded slots 77′and 77″ of non-structural elongated members 74′ and 74″, respectively.The upper arms of L-shaped connectors 90 and 92 are attached tosidewalls 22 and 24 of upper portion 12 of elongated structural strut 10by screws 98 and 100, respectively.

In this embodiment, the ends of flange portions 80′ and 80″ are recessedfrom the ends of upper portions 76′ and 76″ and webs 78′ and 78″, asshown in FIGS. 5 and 7, so that the bottom surfaces of flange portions80′ and 80″ of non-structural elongated members 74′ and 74″ and offlanges 16 and 18 of elongated structural strut 10 form a substantiallyflat surface.

FIG. 7 illustrates one way of connecting the elongated structural strutsand the non-structural elongated members of this invention to formintersecting and perpendicular rows of those struts and members. Inother embodiments, the elongated structural struts and non-structuralelongated members can be attached using different methods/apparatus thatare sufficient to maintain the elongated structural struts and thenon-structural elongated members in the desired relative positions.

As stated, FIG. 8 discloses a partial ceiling grid comprised of aplurality of elongated structural struts 10 and non-structural elongatedmembers 74. The grid is attached to and suspended from a ceiling by aplurality of ceiling rod assemblies 61.

What has been described and illustrated herein are preferred embodimentsof the invention with some variations. The terms, descriptions andfigures herein are intended to be for illustration only and are notmeant as limitations. Those skilled in the art will recognize that manyvariations are possible within the scope of the invention, as defined bythe following claims.

1. An elongated ceiling grid member having a longitudinal axis,comprising: an upper portion; a web that is a plate having a top sideedge and a bottom side edge; and a flange portion that extendsperpendicular to the web; wherein: the upper portion is continuous withthe top side edge of the web and the flange portion is continuous withthe bottom side edge of the web; the upper portion includes (a) a floorportion that (1) includes an upper surface that defines a floor having aflat surface that is perpendicular to the web and (2) is continuous withthe top side edge of the web and (b) first and second spaced sidewallsthat are continuous with and extend upwardly from the floor portion; thefirst spaced sidewall of the upper portion includes a first threadedsurface and the second spaced sidewall of the upper portion includes asecond threaded surface; and the first threaded surface and the secondthreaded surface face each other.
 2. The elongated ceiling grid memberof claim 1, wherein the first and second spaced sidewalls of the upperportion are parallel.
 3. The elongated ceiling grid member of claim 2,wherein: each of the first and second sidewalls of the upper portionhave a top end; and the top end of the first spaced sidewall and the topend of the second spaced sidewall define an opening.
 4. The elongatedceiling grid member of claim 2, wherein each of the first and secondsidewalls of the upper portion is a plate member.
 5. (canceled)
 6. Theelongated ceiling grid member of claim 5, wherein the first and secondspaced sidewalls are substantially parallel to the web.
 7. The elongatedceiling grid member according to claim 6, wherein the first spacedsidewall is on one side of the web and the second spaced sidewall is onthe other side of the web.
 8. The elongated ceiling grid memberaccording to claim 7, wherein the floor portion has a mid-point and theweb intersects the floor portion at the mid-point of the floor portion.9. The elongated ceiling grid member of claim 1, wherein: the floor hasfirst and second longitudinal side edges; the first spaced sidewall ofthe upper portion extends upwardly from the first longitudinal side edgeof the upper portion; and the second spaced sidewall of the upperportion extends upwardly from the second longitudinal side edge of theupper portion.
 10. The elongated ceiling grid member of claim 1,wherein: the floor and the first and second spaced sidewalls of theupper portion form a U-shaped member with square corners.
 11. Theelongated ceiling grid member of claim 1, wherein each of the upperportion, the web and the flange portion are elongated members extendingsubstantially parallel to the longitudinal axis of the elongated ceilinggrid member.
 12. The elongated ceiling grid member of claim 1, whereinthe upper portion, the web and the flange portion are integral.
 13. Theelongated ceiling grid member of claim 1, wherein the flange portionincludes a top surface and the top surface has a longitudinal depressionadjacent and parallel to the web on each side of the web.
 14. Theelongated ceiling grid member of claim 1, wherein the web has acontinuous thickness between the upper portion and the flange portion.15. The elongated ceiling grid member of claim 1, wherein the webincludes first and second opposing flat faces that extend continuouslybetween the top side edge and the bottom side edge.